Method and apparatus for total energy fuel conversion systems

ABSTRACT

Process of producing power comprising:  
     providing a turbine adapted to generate shaft work, said turbine having a combustor; and a rocket engine having a nozzle and a compressor means;  
     feeding fuel and oxidant to the rocket engine and the rocket engine compressor means;  
     feeding carbonaceous matter and steam into the rocket engine nozzle;  
     processing the output of the rocket engine nozzle into fuel for the turbine;  
     introducing said fuel and oxidant for the turbine to the turbine combustor; and  
     recycling a substantial portion of the hot exhaust from the turbine to the rocket engine compressor means; and  
     controlling the inlet temperature to the turbine.  
     Apparatus for producing power comprising a rocket engine and a turbine adapted to generate shaft work is also disclosed.  
     An alternative process comprises  
     providing a steam turbine adapted to generate shaft work; and a rocket engine having a nozzle and a rocket engine compressor means;  
     feeding fuel and oxidant to the rocket engine;  
     feeding carbonaceous matter and water, steam or water-steam mixture to the rocket engine nozzle;  
     processing the output of the rocket engine nozzle into fuel for a boiler and a heat source for a second rocket engine;  
     boiling water in said boiler to produce water vapor;  
     using the resultant water vapor to power said steam turbine;  
     transforming the output of the second rocket engine into a fuel product is also disclosed.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates to conservatively transformingcarbonaceous matter into fuels and petrochemicals for power and otherpurposes.

[0003] 2. Description of the Prior Art

[0004] There have been many attempts to improve the efficiency of powergeneration systems in order to reduce the fuel consumption/powergenerated ratio, and to reduce environmental pollution from combustionproducts. Some of those attempts include gas turbine blade cooling,combined cycle heat recovery, and the Humid Air Turbine (HAT) cycle. Forexample, U.S. Pat. No. 4,829,763 discloses an intercooled, regenerativecycle with a saturator that adds considerable moisture to the compressordischarge air so that the combustor inlet flow contains 20 to 40% watervapor. The water vapor adds to the turbine output while the intercoolingreduces the compressor work requirement which result in higher specificpower. The compressed air which is used for combustion of the fuel todrive the turbine is cooled then humidified prior to combustion in amultistage counter-current saturator with the aforementioned watervapor. Low level heat is rejected from the compressed air duringintercooling and prior to humidification. The HAT cycle is animprovement in thermal efficiency compared to the combined cycle, thesteam injected cycle, the intercooled regenerative cycle and otherhumidification based processes. The HAT cycle requires very high airpressures up to 30 atmospheres and higher turbine inlet temperatures upto 2800 F to improve overall plant thermal efficiencies.

[0005] Another system is considered to be an extension to the HAT cycle,and is called the Integrated Gasification Humid Air Turbine (IGHAT) hasbeen described by Day and Rao as a method of coal gasification basedpower generation that could provide high efficiency and low emissions atleast comparable to an integrated gasification combined cycle (IGCC) butwithout the penalty of high capital cost that is usually associated withIGCC systems. Much of the cost savings from IGHAT comes from the factthat the HAT cycle can use low level heat from gasification quench waterin an efficient way via the saturator, whereas in an IGCC one mustrecover as much heat as possible from the raw coal gas in the form ofhigh temperature and high pressure steam, using relatively expensivewaste heat boilers. Additional cost savings occur because the cycle doesnot require a steam turbine condenser. Further, the large amount ofwater vapor mixed with combustion air is expected to reduce NO_(X)emissions to very low levels, assuming suitable combustion can beachieved at reduced flame temperatures.

[0006] Harvey et al., describe a process for reducing combustionirreversibility through off-gas recycling. The process has no bottomingcycle which is similar to a gas turbine with intercooling, reheating anda regenerator. The regenerator functions as a reformer wherein the fuelis cracked and partly oxidized by heat from the recycled turbineoff-gases. The off-gases contain oxygen and thus are used as oxygencarriers. Before each turbine stage, air is injected into the gas streamcontaining reformed fuel and recycled off-gases which are therebysequentially fired. The water vapor in the off-gases is partiallyliquefied in the series of water-cooled condensers after each stage;intercooling is accomplished by injection of the water. Analysis byHarvey, et. al. shows reforming for fuel conversion, but the gainspresented were limited by pinch point temperature in the reformer.Harvey, et al. plan further study of the effect of their proposedarrangement on efficiency at turbine inlet temperatures below 2300 F,which in the analysis is the approximate high limit without turbineblade cooling.

[0007] To control turbine inlet temperature within acceptablemetallurgical limits (now 2600-2800 F) gas turbine designers haveresorted to excess combustion air, diluents such as steam as in HAT orsimple steam injection, water injection or compressor intercooling.Concurrently metallurgists are working to develop ceramic components orcoatings which can tolerate ever higher temperatures. This inventionachieves turbine inlet temperature control by turbine exhaust recyclewith consequential high system cycle efficiencies. Capital is reduced byrocket engine reactor compactness and elimination of combined cycleequipment and its related efficiency reducing system infrastructure. Indealing with the exhaust from steam turbines, this invention utilizesmuch of the latent heat in the exhaust with consequent reduction in thecooling water load otherwise required for condensing steam for boilerfeed water.

[0008] It is therefore an object of the present invention to provide amethod of generating power from fuel with improved efficiency over priormethods, employing conventional turbine inlet temperatures withoutdiluent injection or intercooling. Another object is to provideapparatus for generating power from fuel in a more flexible, efficientand less polluting manner than prior art methods, at reduced capitalcost.

[0009] This invention can also be used as a pyrolysis reaction system tocarry out either moderate temperature conventional pyrolysis or hightemperature total pyrolysis. U.S. patents by Raniere, et al. U.S. Pat.No. 4,724,272 and Hertzberg, et. al. U.S. Pat. No. 5,300,216 teach thatheating and quench in transonic flow must be accomplished at preciseresidence times with respect to shock type and shock location. Bothhydrocarbon and steam are heated and passed through separate supersonicnozzles before pyrolysis. Hertzberg further teaches that, afterquenching, the cracked gases may be passed through a turbine for energyrecovery and further cooling.

[0010] With this invention combined fuel conversion transformations andpyrolysis are also possible. U.S. Pat. Nos. 4,136,015 and 4,134,824 byKamm, et. al. teach a process for thermal cracking of hydrocarbons andan integrated process for partial oxidation and thermal cracking ofcrude oil feed stocks. Hydrogen available from heavy oil partialoxidation promotes yield selectivity. Moderate time-temperature crackingconditions are selected which result in substantial liquid product andtar yields which must be handled with difficulty within their processand in downstream processes.

[0011] It is therefore an object of this invention to provide a methodof pyrolyzing and hydropyrolyzing carbonaceous matter either alone or incombination with fuel conversion transformations at moderate or hightemperatures and pressures, achieving near total feed stock conversion,in a near total energy conservation arrangement. Another object of thisinvention to provide apparatus for pyrolyzing and hydropyrolyzingcarbonaceous matter either alone or in combination with fuel conversiontransformations at moderate or high temperatures and pressures,achieving near total feed stock conversion, in a near total energyconservation arrangement.

SUMMARY OF THE INVENTION

[0012] These objects, and others which will become apparent from thefollowing disclosure, are achieved by the present invention whichcomprises in one aspect a process of producing power comprising:

[0013] providing a turbine adapted to generate shaft work, said turbinehaving a combustor; and a rocket engine having a nozzle and a compressormeans;

[0014] feeding fuel and oxidant to the rocket engine and the rocketengine compressor means;

[0015] feeding carbonaceous matter and water and/or steam to the rocketengine nozzle;

[0016] processing the output of the rocket engine nozzle into fuel forthe turbine;

[0017] introducing said fuel and oxidant for the turbine to the turbinecombustor to produce carbon dioxide and water combustion products;

[0018] passing said combustion products through the turbine;

[0019] recycling a substantial portion of the hot exhaust from theturbine to the rocket engine compressor means;

[0020] further recycling the hot exhaust from the rocket enginecompressor means to the rocket engine nozzle; optionally into one ormore secondary port downstream from said nozzle; and optionally as acompressed flow for other uses.

[0021] controlling the inlet temperature to the turbine.

[0022] In another aspect, the invention comprises apparatus forgenerating power from fuel comprising:

[0023] a turbine having a combustor;

[0024] a rocket engine having a nozzle and a compressor means;

[0025] means for adding carbonaceous matter and water and/or steam tothe rocket engine nozzle;

[0026] means for feeding fuel and oxidant to the rocket engine and tothe rocket engine compressor means;

[0027] means for processing the output of the rocket engine nozzle intofuel for the turbine combustor;

[0028] means for introducing said fuel and oxidant for the turbine tothe turbine combustor to produce carbon dioxide and water combustionproducts;

[0029] means for recycling a substantial portion of the hot exhaust fromthe turbine to the rocket engine compressor means;

[0030] means for further recycling the hot exhaust from the rocketengine compressor means to the rocket engine nozzle; optionally into oneor more secondary ports downstream from said nozzle; and optionally as acompressed flow for other uses; and

[0031] controlling the inlet temperature to the turbine;

[0032] Another aspect of the invention is an alternative process ofproducing power comprising:

[0033] providing a steam turbine adapted to generate shaft work; and arocket engine having a nozzle and a rocket engine compressor means;

[0034] feeding fuel and oxidant to the rocket engine;

[0035] feeding carbonaceous matter and water and/or steam to the rocketengine nozzle;

[0036] processing the output of the rocket engine nozzle into fuel for aboiler and fuel for a second rocket engine;

[0037] boiling water in said boiler to produce water vapor;

[0038] using the resultant water vapor to power said steam turbine;

[0039] quenching the turbine outlet steam with water; recycling thecooled steam and water mixture to the rocket engine nozzle; and

[0040] transforming the output of the second rocket engine into a fuelproduct.

BRIEF DESCRIPTION OF THE DRAWINGS

[0041]FIG. 1 is a diagram of a rocket engine power source comprised of arocket engine, a rocket engine compressor means, a conserved energyreactor and a distribution means.

[0042]FIG. 2 is a diagram of a rocket engine power source flowing to anexpansion turbine whose exhaust is recompressed by a prime mover so thatmost of the compressor discharge is effectively recycled to a conservedenergy reactor.

[0043]FIG. 3 is a diagram of a rocket engine power source flowing to anexpansion turbine which is part of an existing gas turbine withproductive use of its connected compressor.

[0044]FIG. 4 is a diagram depicting the rocket engine power sourceflowing to three expansion turbines in series interspersed with separatecombustors with independent oxidant supplies from the rocket enginecompressor means.

[0045]FIG. 5 is a diagram depicting a rocket engine power source incombination with a fuel cell and a second conserved energy reactor andan expansion turbine to optimize the base load and/or peak load forpower delivery.

[0046]FIG. 6 is a diagram depicting a rocket engine power sourceintegrated with a boiler and using two stage fuel transformations.

[0047]FIG. 7 is a diagram depicting a rocket engine power source and aboiler with a hot gas flow extension to further improve systemefficiency.

[0048]FIG. 8 is a diagram depicting two rocket engine power sources in acombined process for pyrolysis and fuel transformation to produceethylene and synthesis gas.

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENTS

[0049] The process of producing power comprises:

[0050] providing a turbine adapted to generate shaft work, said turbinehaving a combustor;

[0051] and a rocket engine having a nozzle and a compressor means;

[0052] feeding fuel and oxidant to the rocket engine;

[0053] feeding carbonaceous matter and water and/or steam to the rocketengine nozzle;

[0054] processing the output of the rocket engine into fuel for theturbine combustor;

[0055] introducing said fuel for the turbine to the turbine combustor;

[0056] passing combustion products through a turbine; and

[0057] recycling a substantial part of the hot exhaust from the turbineto the rocket engine compressor means:

[0058] further recycling of the exhaust from the rocket enginecompressor means to the rocket engine nozzle; optionally one or moresecondary ports downstream from said nozzle; and optionally a compressedflow for other uses; and

[0059] controlling the inlet temperature to the turbine.

[0060] Suitable gas turbines adapted to generate shaft work includestandard and advanced commonly available gas turbines manufactured byGE, ABB, Solar, Siemens and others.

[0061] Suitable gas turbine combustors include combustors provided withthe gas turbines or those specially designed for high steam operation.

[0062] Suitable rocket engines include jet engines manufactured by G E,Pratt & Whitney, Rolls Royce and others; and burners made by T-Thermal,John Zink and others; and jet and rocket engines made by manufacturersof propulsion systems for magnetohydrodynamic generators up to 5000 Fstagnation temperatures such as TRW.

[0063] Suitable nozzles for rocket engines include deLaval typecontracting/expanding nozzles.

[0064] Suitable fuels for the rocket engine include methane, natural gasand petroleum distillates.

[0065] Suitable oxidants for the rocket engine reactor include air andoxygen.

[0066] Suitable processing the output of the rocket engine nozzle intofuel for the turbine combustor includes one or more near-adiabatictunnels and nozzles sized to generate one or more shock waves andproduce jet propulsions to boost flow energy.

[0067] Suitable temperatures for introducing fuel for the turbine to theturbine combustor so that turbine inlet temperature is controlled withinexisting materials limitations, i.e., up to 2800 F for new gas turbines.

[0068] Suitable means for recycling hot exhaust from the turbine to therocket engine compressor include gas turbines, turbochargers, dieselengines and other internal combustion engines.

[0069] Preferably the output from said rocket engine nozzle and saidrecycled hot exhaust gas from said turbine are transformed in anear-adiabatic atmosphere into said fuel for said turbine. Bynear-adiabatic atmosphere is meant that heat content of fuel gas,oxidant, carbonaceous matter and water being fed are preserved exceptfor unavoidable radiation or other losses to the environment.

[0070] In certain embodiments, carbonaceous matter is introduced intosaid output of said rocket engine reactor downstream of said nozzle atvelocities sufficient to transform said carbonaceous matter into saidfuel for said turbine. Suitable velocities for such transformationinclude sub-sonic and supersonic flow up to Mach 2 and higher tocomplete reactions and deliver flow at turbine inlet pressure.

[0071] The carbonaceous matter is preferably methane, but canalternatively be natural gas and its components, petroleum coke, residuaor distillates, biomass, coal, char or other chemicals suitable forpyrolysis or combustion. Preferably said fuel is also methane.

[0072] In some embodiments a portion of said hydrogen is diverted to oneor more downstream uses, for example fuel cells, iron oxide reductionreactors, or chemical processes such as petroleum distillatehydrodesulfurization, hydrogenation of unsaturated hydrocarbons, ammoniaand alcohol production, etc. In some embodiments, a portion of saidhydrogen or other fuel is recycled by suitable means to fire rocketengine and downstream jet propulsions.

[0073] When the transformation occurs in a group of transformationreactors it is preferred that the pressure in said output of said rocketengine compression means conforms by suitable means with the pressure ineach transformation reactor.

[0074] In certain embodiments a portion of said hot exhaust from saidturbine combustor is compressed in an intermediate compressor andrecycled directly to a short circuit distribution means and delivered asheat and mass additions at least matching or boosting pressure,jet-like, at suitable junctures augmenting said hot exhaust.

[0075] Generally, the output of said rocket engine nozzle exits fromsaid nozzle at transonic speeds. By transonic speeds is meant near sonicand supersonic up to Mach 2 and higher, suitable to the processreactions and maintenance of designed flow energy level.

[0076] When reaction severity or selectivity in the transformationreactor or series of reactors needs to be increased or when more mildoperations conditions are desired, catalyst for said transformation isintroduced into said output of said rocket engine nozzle. Suitablecatalysts include manganese oxide and zinc titanate.

[0077] The shaft work of the turbine can be for electrical generationonly, or can also include work to operate one or more compressors orpumps.

[0078] One or more turbines, one or more combustors, and one or moreelectrical generation means are possible.

[0079] In certain embodiments, supplemental or interstage oxidant isadded to said turbine combustor(s). The oxidant can be introduced insaid turbine combustor(s) to effectively control turbine inlettemperature. Suitable temperatures for turbine blades and components areabout 1700 F for older gas turbines up to about 2800 F for current stateof the art designs. Turbine inlet temperature can be increasedconsistent with improvements in materials technology for highertemperature and higher efficiency operations.

[0080] Generally one product of said transformation is hydrogen. Otherproducts can be carbon dioxide, carbon monoxide, and water vapor, forexample.

[0081] Another embodiment of the invention is a process of producingpower comprising: providing a steam turbine adapted to generate shaftwork; and a rocket engine having a nozzle and a compressor means;

[0082] feeding carbonaceous matter and steam to the rocket enginenozzles;

[0083] feeding fuel and oxidant to the rocket engine;

[0084] processing the output of the rocket engine nozzle into fuel for aboiler and fuel for a second rocket engine;

[0085] boiling water in said boiler to produce water vapor;

[0086] using the resultant water vapor to power said steam turbine;

[0087] quenching the turbine outlet steam with water; and recycling thecooled steam and water mixture to the rocket engine nozzle; and

[0088] transforming the output of the second rocket engine into a fuelproduct. The fuel product generally comprises hydrogen.

[0089] In some embodiments clean water is introduced into saidtransformation reactor or group of transformation reactors, therebyreacting in said reactor or reactors with said output of said rocketengine. Preferably, the clean water is introduced in an approximatelyequal or greater weight ratio with the steam turbine exhaust.

[0090] Preferred embodiments of this aspect of the invention includeproviding a heat exchanger; a third rocket engine having a nozzle; a gasturbine having a combustor; feeding fuel and oxidant to said thirdrocket engine; directing the output of said third rocket engine nozzleinto said heat exchanger so as to cool said output and tosuper-superheat steam from said boiler; and transferring the resultantsuper-superheated steam to said steam turbine.

[0091] One suitable apparatus for generating power from fuel accordingto the invention comprises: a gas turbine having a combustor; a rocketengine reactor having a nozzle and a compressor; means for feeding fueland oxidant to the rocket engine;

[0092] means for processing the output of the rocket engine reactor intofuel for the turbine combustor; means for introducing said fuel for theturbine to the turbine combustor;

[0093] means for recycling hot exhaust from the turbine to the rocketengine compressor means;

[0094] means for further recycling the exhaust from the rocket enginecompressor means to the rocket engine nozzle; optionally the secondaryports downstream from said nozzle; and optionally as a compressed flowfor other uses; and for controlling the inlet temperature to the gasturbine.

[0095] The high pressure high temperature gas turbines being developedmay, with cost effective revisions, may be retrofitted according to thisinvention to increase their thermal efficiencies. Perhaps the greatestretrofit gains will redound to the many heavy-duty, low efficiency,stationary gas turbines already installed and operating in a lowertemperature range. Apart from the heat recovery via conserved recyclerecompression, the implementation of the independently poweredcompressor can completely eliminate the work of compression from theoutput power expansion turbine, thereby increasing its output net workand mechanical efficiency. This same gain is accordingly obtained with anew installation.

[0096] This invention achieves turbine inlet temperature control byturbine exhaust recycle with consequential high system cycleefficiencies. Capital is reduced by rocket engine reactor compactnessand elimination of combined cycle equipment and its related efficiencyreducing system infrastructure. Nitrogen oxides normally associated withhydrogen production by steam reforming are reduced due to high steam,low air or nitrogen free reaction conditions and increased thermal cycleefficiency.

[0097] As mentioned, the invention comprises recycling a substantialpart of the exhaust gases from an expansion power turbine; augmentingthem with fuel additions and the combustion products of said fueladditions for compressing them; recompressing them in an independentheat conserving, staged jet compression process and returning them tothe expansion power turbine; reacting said gases in a toppingcompression stage with a rocket engine-driven water-gas shifthydrocarbon transforming and/or water gas shift reactor (hereinafterreferred to as the conserved energy reactor), for added thermochemicalconversion resulting in recyclable fuel and extra fuel for otherpurposes outside the expansion power cycle; and; modulating turbineinlet temperature by controlled recycling of augmented turbine exhaustflows. The present invention extends the art by improving efficiency,reducing gasification capital and minimizing environmental pollution;and adds capabilities beyond the state of the art by carrying out theshift and other transforming reactions in another conserved energyreactor.

[0098] Shift reaction converts carbon monoxide to carbon dioxide andadditional hydrogen. Sequential conserved energy reactor designs willfurther reduce capital and improve process plant and power generationeconomics.

[0099] Referring now to the drawings, FIG. 1 show carbonaceous matter100 and water 99 as feeds to the secondary ports of rocket engine nozzle120. A rocket engine 102 is fueled through line 101, preferably methane.The oxidant, preferably air, is delivered to rocket engine 102 at toppressure via line 103 from the oxidant source. Oxidant is optionallybranched on line 104 to gas turbine combustor 105. Combustor 105 is alsofired with fuel 106 to control the turbine inlet turbine inlettemperature in combination with water 107.

[0100] Hot exhaust gases from combustor 105 expand through gas turbine108. The exhaust from the turbine in line 109 can be directed as 1110into any one or more of secondary ports to downstream nozzles viarelated lines 111, 112 and 113; or a portion or all of it as 114 can bebranched off to join and become recoverable heat fluids carried in line115. As an alternate to the flow in 114, the flow 116 into compressor117 delivers the flow as 118 at system pressure to accommodate heat andmass balance for the cycle. A further branch 119 can be directed to thesecondary port of nozzle 120. Transforming reactors 121, 122 and 123respectively represent water-gas, shift, and extended residence timezones where transformation of rocket engine exhaust occurs. These zonescan be programmed optionally as sequential transonic shock zones orsimply as two or more residence time zones. Down-stream thrusts can beprogrammed by after-jet combustion by introducing oxidant through lines124, 125 and 126 to fire with unreacted carbonaceous matter.

[0101] Un-utilized lines among 111, 112, 113, 124, 125 and 126 can beprogrammed to introduce other reactive matter. The extent of the usesdepends on the reactivity of the compounds present. A clean reactant forconversion, methane for example, into an auxiliary port of nozzle 120may require no more than two reaction zones. A pre-cleaned coal orpetroleum coke could require an additional zone. Solid feed stocksadditionally require the separation of particulates from the flow whichwould take place in particle separator 127. Another use for separator127 can be to recover particles secondarily entrained for any one of thefollowing functions by discharging:

[0102] 1. Catalyst Particles;

[0103] 2. Getter Minerals for alkali metal capture in biomass processes;

[0104] 3. Sulfur Capturing Seeds like manganese oxide or zinc titanatefor coal, coke and residual oils;

[0105] 4. Iron Particles for Steam Iron Reactions to produce spongeiron, produce hydrogen for fuel cells and other uses, and torecycle-reduce iron oxides;

[0106] 5. Other Metal Particles like tin and zinc for thermochemicalreactions; and

[0107] 6. Neutral Particles for heat transfer to lighter faster flowingparticles, gases and vapors.

[0108] Any one or more of the above can be introduced by entrainment ina fluid that is chemically compatible to the process. Some processes mayrequire at least one more separator 127 which may be in a cascade seriesmanifolded so that the product gas flows totally into nozzle 128 whichcan serve as a back pressure for the following process uses natural gas,cleaned or pre-cleaned carbonaceous matter is converted for directcombustion for turbine expansion, or an integrated fuel cell/turbineprocess. One capability of the rocket engine driven reactor train is toproduce a fuel gas to be used directly in combustion, as in laterembodiments. Another capability of the rocket engine driven reactortrain is to force the reactions to completion towards the lowestreaction end temperature by programmed, metered and controlled reactantfeeds. This is useful when maximum hydrogen production is desired forsubsequent chemical use. Most conversion reactors in practice quench thereaction to preserve its final chemical composition. By contrast, whenappropriate this invention fires the product gas at the end of thereaction for the stoichiometrically prescribed reaction end temperaturewhich ends at station 129 of the conserved energy reactor distributionmeans.

[0109] On the other hand, when the reaction end temperature does notconform to still lower temperatures required by downstream processing,then the reaction must be quenched. Conversely, a process such aspyrolysis can require quenching to interrupt a reaction sequence andfreeze desired intermediate chemical species. Examples would includecracking of methane to produce acetylene and ethylene; cracking ofethane to produce ethylene; and cracking of propane, butane andpetroleum distillates to co-produce hydrogen, ethylene, propylene,butylene, butadiene and other diolefins, and aromatic compounds.

[0110] When oxygen is the oxidant of choice and its source is availableover the fence at pressure for the process, the need for a separateoxygen compressor means is eliminated. Otherwise a compressor means canserve to boost the pressure of the oxygen.

[0111] Line 130 shown branching off oxidant source is to provide oxygenor air to any one or more of the secondary ports to nozzle stations 120,131, 132 and 128 for increasing the thrust in the flow by after-jetcombustion. An ignition source is provided when the flow on contact isbelow the auto-ignition or reaction temperature. Ignition lines are notshown but are similar to line 133. The function of after jet combustionis to boost entrainment, create shock, and/or make up for friction headloss to maintain pressure at station 129.

[0112] Compressor 134 is shown powered by combustor 105 and turbine 108.However compressor 134 can be powered by any prime mover, a dieselengine for example, providing preferably that its fuel composition ischemically compatible with flow in the conserved energy reactor;otherwise the exhaust must be exported for recovery uses.

[0113] Standard equilibrium plots are used as guidelines for startingand running the conversion process so as to avoid the formation of solidcarbon or coke.

[0114] This process has the capability for making extra products, forexample, synthesis gases for ammonia or alcohols, pyrolysis crackedgases for ethylene and petrochemicals can be produced.

Typical Baseline Reactions for the Conserved Energy Reactor

[0115] The following are the main equations which relate selectively toany embodiment incorporating the conserved energy reactor described withrespect to FIG. 1. The basic equations are as follows: $\begin{matrix}{\left. {C + {H_{2}O}}\rightleftharpoons{{CO} + {H_{2}\quad \Delta \quad H}} \right. = {{+ 28}\quad {kcal}\quad {Water}\quad {Gas}}} & {{Equation}\quad (1)} \\{\left. {{CO} + H_{2} + {H_{2}O}}\rightleftharpoons{{CO}_{2} + {2H_{2}\quad \Delta \quad H}} \right. = {{- 9.8}\quad {kcal}\quad {Shift}}} & {{Equation}\quad (2)} \\{\left. {{CH}_{4} + {H_{2}O}}\rightleftharpoons{{CO} + {3H_{2}\quad \Delta \quad H}} \right. = {{+ 49.3}\quad {kcal}}} & {{Equation}\quad (3)} \\{\left. {{CH}_{4} + {2H_{2}O}}\rightleftharpoons{{CO}_{2} + {4H_{2}\quad \Delta \quad H}} \right. = {{+ 39.5}\quad {kcal}}} & {{Equation}\quad (4)}\end{matrix}$

[0116]FIG. 1 also shows how additional fuel can be produced in additionto increasing the efficiency of the power cycle. It shows the reactordischarging 3H₂+N₂ as synthesis gases for the ammonia process andadditional fuel as H₂+0.333N₂ which can be used for more steam ortowards fueling the rocket engine for export within the plant.

[0117] The following two equations illustrate the basic autothermalreactions taking place in the reactor to produce these gases$\begin{matrix}{{\left. {{CH}_{4} + {2H_{2}O}}\rightleftharpoons{{CO}_{2} + {4H_{2}\quad \Delta \quad H}} \right. = {{+ 39.5}\quad {kcal}}};{and}} & {{Equation}\quad (4)} \\{\left. {{0.176\quad {CH}_{4}} + {2H_{2}O} + {0.353O_{2}} + {1.333N_{2}}}\rightarrow{{0.176{CO}_{2}} + {0.353H_{2}O} + {1.333N_{2}\quad \Delta \quad H}} \right. = {{- 33.6}\quad {kcal}}} & {{Equation}\quad (5)}\end{matrix}$

[0118] The sum of the reactions (4) and (5) yield the following:        4H₂ + 1.333N₂ Ammonia synthesis gases 1.176CO₂ + 1.333N₂ Surplusfuel for increased stem flow and/or reactor recycle; or plant export1.176CO₂ + 1.333N₂ Also for plant export

[0119] This is another special feature of this process i.e. theprovision for making extra products. The synthesis gases for ammonia canalso be produced in later embodiments employing gas turbines. The watergas shift equations (1) through (4) may be applied to all theembodiments of this invention depending on the carbonaceous matter to beconverted. Methane or natural gas relate to equations (3) and (4)whereas coal, petroleum coke and biomass and residual oils can beprocessed via the water gas shift equations (1) through (2). The watergas reaction yields H₂+CO generally from the first reactor and shown aslines 141 and 142 depending on the ultimate use as process fuel gas orsynthesis gas. The significance of equilibrium in this invention isexplained with respect to Equation 4 for example which produces fourmoles of hydrogen and one mole of carbon dioxide. For practical purposesa nearly straight line relationship holds in the positive log₁₀ K scalefrom five to zero corresponding to temperatures respectively from 1600 Kto 880 K (Wagman, et. al.), or 2400 F to 1100 F approximately. Highertemperatures of course also favor equilibrium. (Equilibrium constants byWagman, et. al.)

[0120] In order to understand the particular significance of equilibriumwith this invention is to conceptualize a very high temperature jet, say4000 F, rich in steam progressively completing equilibrium particle byparticle of interacting carbonaceous matter as they travel down theprogressively decreasing log₁₀K function and corresponding temperaturesdown to 1100 F and lower because it is possible with pressure to do soto a minor extent in the negative log₁₀K range. Driving to lowtemperature is beneficial if the fuel gas must be desulfurized. It alsois sometimes useful in this case to separate the carbon dioxide from thehydrogen as shown with lines 143 and 144. A further advantage whendriving a stoichiometrically specified reaction to completion at a lowtemperature is that less carbonaceous matter or fuel and less oxygen isrequired for the endothermic heat which results in less carbon dioxidein the off-gases.

[0121] On the other hand, if a pre-cleaned coal is the reactant, it canbe useful to drive the reaction to a higher end temperature for use inturbine combustor 129, whereby the reaction is set by firing throughline 133. However, a pre-cleaned coal generated fuel gas must have itsfly ash removed in separator 127 through line 145 Before being fired incombustor 129.

Flexibility for Pyrolysis

[0122] This invention can also be used as a pyrolysis reaction system asshown in FIG. 1 to carry out either moderate temperature conventionalpyrolysis or high temperature total pyrolysis. At moderate temperaturesethane, propane, butane and petroleum distillates may be cracked toproduce ethylene and acetylene and other olefins and diolefins such aspropylene, butylene, butadiene and aromatic hydrocarbon liquids. At hightemperatures, methane may be cracked to produce mainly hydrogen,ethylene, and acetylene. Cracking non-methane hydrocarbons at hightemperatures yields virtually total conversion to yield a productdistribution largely free of the normally produced cyclic compounds,aromatics and heavy aromatic oils and tars.

[0123] U.S. patents by Raniere, et al, U.S. Pat. No. 4,724,272 andHertzberg, et al. U.S. Pat. No. 5,300,216 teach that heating and quenchin transonic flow must be accomplished at precise residence times withrespect to shock type and shock location. Those skilled in the art knowthat rapid quench to a temperature about 1100-1300 F is important topreserve yields of desired products and minimize coke formation.

[0124] The rocket engine 102 and nozzle section 120 of this inventioncoupled to reactors 121, 122 and 123 previously described represent afacility having flexible reactor length, capability for creatingdifferent shock characteristics along the reaction path and forquenching through ports 111, 112, 125 and 126 at different reactiontime-temperature cracking severities. Many degrees of freedom areavailable since any one or more of said locations and including nozzlesection 120 ahead of the selected quench locations can optionally beused for transonic mass inputs and heat additions to the main flow.Quenching can be total or partial and direct or indirect or acombination. Direct quench media may be water, steam, hydrocarbons andinert gases. Indirect quench is accomplished in a heat exchanger (notshown) at or near location 127 instead of the separator shown. Thequenched cracked products are discharged through nozzle section 28 anddistributed via line 146 to be further processed by suitable means.

Flexibility for Combined Production of Synthesis Gas and CrackedProducts

[0125] U.S. Pat. Nos. 4,136,015 and 4,134,824 by Kamm, et. al. teach aprocess for thermal cracking of hydrocarbons and an integrated processfor partial oxidation and thermal cracking of crude oil feed stocks.Moderate time-temperature cracking conditions are selected which resultin substantial liquid product and tar yields which must be handled withdifficulty within their process and in downstream processes.

[0126] With this invention, combined fuel conversion transformations andpyrolysis are also possible. High temperature operation is preferred sothat complete breakdown and conversion of normally liquid or solidcracked hydrocarbon products is achieved. In combined mode synthesisgasses are first produced in one or more conserved energy reactors aspreviously described. Then, in a downstream conserved energy reactor,pyrolysis reactants are introduced to the high steam and high hydrogensynthesis gases flowing from the first conserved energy reactor andtotal pyrolysis is carried out as previously described. The presence ofhydrogen in relatively large quantities during pyrolysis adds to yieldselectivity towards desired products. The presence of steam inrelatively large quantities during pyrolysis reduces tendency for sootor coke formation.

[0127] To further enhance reactivity, further accelerate heating ratesand further improve selectivity towards desired cracked productssupplemental oxidant may be added through available secondary nozzleports. In combined fuel transformation—pyrolysis mode direct waterquenching is preferred since the steam thus produced in situ is usefulin generating turbine power. Cracked products are passed through aturbine for further cooling by isentropic extraction of work and flow toother conventional separation processes. Either high temperature ormoderate temperature pyrolysis can be practiced depending upon feedstock, desired end products and economic factors. Direct or indirect orcombination reaction quenching can be practiced depending upon feedstock, desired end products and economic factors.

[0128]FIG. 8 is a diagram of a pyrolysis and fuel transformation processfor ethylene and synthesis gases. The process to be described isrepresentative in general of producing other hydrocarbons. Methane isfed through compressor 134 and is distributed to suit a high pressure inline 800 into combustor 102, line 801, nozzle section 120 and line 802as an option for after jet combustion. A fraction of the methane isfired with oxygen is combustor 102 for the endothermic requirement ofthe ensuing transformation reaction in the form of

CH₄+H₂O

CO+3H ΔH=+49.3 kcal  Equation (1)

[0129] The remaining methane in combustor 102 serves to augment the massof the jet. The synthesis gases produced in the conserved energy reactoris distributed to suit three different purposes:

[0130] 1. A fraction is recycled to fuel combustor 105 of the rocketengine compressor means. The resulting exhaust from turbine 108 isrecompressed by compressor 117 and is distributed along the reactor asshown;

[0131] 2. A fraction is synthesis gas product; and

[0132] 3. The remaining fraction is fed under pressure to a second stagerocket engine combustor and fired with oxygen to form the pyrolysis jetin the form and range of

CO+2H₂O TO CO₂+3H₂O

[0133] to crack ethane for the production of ethylene as previouslydescribed.

[0134] As previously described, the combustor of the rocket engine canoperate at stagnation temperatures up to 5000 F and relatively unlimitedstagnation pressures. The conserved energy reactor flexibility for shocklocation and down stream supplemental shocks were also described. Asanother note, methane, carbonaceous matter such as coal and residual oilmay be processed which then produce syngas in the form and range of

CO+H₂ TO CO₂+2H

[0135] Finally, quenching to 1300-1000 F is required with water, steam,a hydrocarbon or inert gas at the point of optimum cracking severity inorder to freeze the desired intermediate reaction products. Any fly ashis removed in the separator at location 127.

[0136] Many other transformation reactions according to the inventiontake place at near sonic and supersonic conditions with high relativeslip velocities between reactants which break into shock zones withensuing subsonic flows. Intense reactivity is obtainable thereby withprimary jet temperatures up to 5000 F (practiced in magnetohydrodynamicflows) and unlimited high pressures for practical purposes.

[0137] Turning now to pressure, increased pressure is known to favormany chemical reactions. As noted earlier, low pressures are suitablefor biomass gasification. It is also well known that biomass is mucheasier to gasify than coal with reactions occurring at lowertemperatures and near atmospheric pressure. Coal is optimally processedat higher pressures.

[0138] This invention incorporates suitable alternatives for varyingreactor pressure for conversion and at the same time conserves therocket engine power source energy for conversion by the recyclefunction.

[0139] The distribution of pressure is as previously described withrespect to FIG. 1 whereby the flow of recoverable heat fluids fromcompressor 134 is branched off to line 136 to supply combustor 105. Theremaining flow is divided into a branch line 137 supplying rocket enginecombustor 102 and branch line 138 to supply any one or more auxiliaryports down stream of power nozzle jet 120.

[0140] Flows in 137 and 138 are not necessarily fixed. Increasing theflow in 137 causes a corresponding decrease in 138. Being able tocontrol this interchange allows more or less temperature in combustor102 for whole or partial oxidation which can have the opposite effectfrom oxidant flow through branch 138, and this can be offset with moreor less carbonaceous feed and water through lines 100 and 99.

[0141] A similar branching interchange is effected from exhaust line 109from turbine 108. This was previously explained as a routine routing.This interchange significance reported here relates to recovery ofexhaust heat and mass. In relatively low pressure operations all or mostof the flow through line 109 can continue through line 110 and bedistributed selectively along and down stream into the reactor. Forprocess reasons or for a stronger entrainment effect the same flow canbe redirected through line 119 where the combustion jet has the mostentraining effect, which effect can be further amplified by increasingthe temperature in combustor 102.

[0142] The need for directing the exhaust flow through line 116 to bemechanically compressed with the oxidant flow in line 139 throughcompressor 134 is less here because of the low pressure characteristicof the process. However, similar functions occur in later expansionturbine embodiments which operate as high as 30 atmospheres at station129. Station 129 then serves as the high pressure high temperaturecombustor of the turbine. In that event recoverable heat fluids line 115are replaced by a large portion of the exhaust which is recompressedalong with the flow in line 116. Then the recoverable heat fluids supplyto all combustors is from another source to be later described for therespective embodiments. In every case, however, power developed by therocket engine and its compressor means must maintain in steady staterecycle flow of consistent chemical composition in a near-adiabaticcycle while conserving a substantial portion of the exhaust energy formore efficiently powering an expansion turbine means which deliversmechanical power or electricity.

[0143] In this event to recover a substantial portion of the exhaustheat and mass, the flexibility afforded by the above described branchinginterchange options from line 109 will serve to optimize the recyclesystem to deliver a constant and consistent mass flow to combustor 129,here powering the expansion turbine means. Most of the heat returningthrough the system will convert carbonaceous matter to fuel gas for thecombustor at station 129. Any additional sensible heat in the flow tostation 129 is conserved to flow through the gas turbine 140. To preventbuildup in recycle, the necessary export carbon dioxide, nitrogen andminimal water vapor will serve to preheat fuel, recoverable heat fluidsand other plant uses. These will be further described in theirrespective embodiments.

[0144] The invention can comprise expansion turbines; turbines withparasitic shaft work, and multiple turbine arrangements.

[0145] Case 1—Rocket Engine Power Source for Single and Multi-StageTurbines

[0146] In FIG. 2 combustor 129 for the expansion turbine means 200delivering power to generator 201. Any mechanically transmitted powerload can be used. The turbine means can be a single turbine, a straightmulti-stage turbine, or a multi-stage turbine with interstage heating.Preferably, the source of temperature and pressure which developed incombustor 129 is the rocket engine power source previously describedwith respect to FIG. 1. The rocket engine power source also includes theconserved energy reactor or transformer. Its function is not only totransform carbonaceous matter introduced through line 124 into a usableproduct fuel gas into combustor 129 but to convert all or most of thepower expended in compressing and heating in the rocket enginecompressor means, rocket engine and conserved energy reactor togetherinto product fuel gas (and its sensible heat) flowing into combustor129.

[0147] The encompassing function of this embodiment is to recycle asubstantial portion of the exhaust part from the last turbine of saidexpansion means, except what must be exported from the cycle (at leastfor direct heat and mass transfer) to prevent build-up in the process.Accordingly, the exhaust 202 branches off at 203 and continues on as 204after being increased in pressure through compressor 205, for interstageheating in turbine means 200. Compressor 205 to be powered by turbine108 can be independently speed controlled by a suitable means.

[0148] It is essential that the mass and chemistry of the greater oroverall cycle remain at steady state; so export mass 206 must bereplaced by an equivalent mass with a conforming aggregate chemistry forcontinuity. For example, if CH₄ is the fuel of choice, reaction incombustor 129 is organized as follows:

CH₄+2 Air+x recycle

CO₂+2H₂O+7.5N₂+xRecycle  Equation (1)

[0149] where Recycle=CO₂+2H₂O+7.5N₂ and where x is higher the lower thedesign turbine inlet temperature, whereby x (CO₂+2H₂O+7.5N₂) cansubstitute for any excess air firing in common practice. Equation (1) isrewritten as follows when oxygen is the preferred oxidant:

CH₄+2 Oxygen+x Recycle

CO₂+2H₂O+xRecycle  Equation (2)

[0150] where Recycle=CO₂+2H₂O whereby x (CO₂+2H₂O) is the substitute forthe excess air. The x term can be any number or mixed number. The flowexported at 206 must equal CO₂+2H₂O but can be fractionally larger forcycle balance as long as its equivalent chemical aggregate reenters thecycle for mass flow continuity.

[0151] Returning now to compressor 134 whereby the fuels for rocketengine 102 and combustor 105 are methane fractions of the design heatvalue, considered to be the sum of heats arriving at combustor 129including any after-jet combustion additions. Compressor 134 receivesand discharges flow 207 which is branched into 208, 209 and 210. Line208 goes into combustor 105 and its main function by proportion is togovern the inlet temperature of combustor flow 209 into turbine 108 oversuitable range for recycle balance whereby the fraction of flow 210becoming 211 is optional on balance from zero flow to a maximum equal tothat of 210. It follows then when 210 is something greater than zero onbalance, it is held on zero for start-up. The compatibility of therocket engine, or in combination with downstream after-jet combustionpropulsions depends on the difference between the top pressure incombustor 102 and the design pressure for combustor 129. Combustors 102and 129 make up more than just marginally the following head losses:

[0152] 1. Rocket Engine Nozzle

[0153] 2. Friction

[0154] 3. Propulsion Entrainment

[0155] 4. Rocket Engine Compressor Means Exhaust Distribution

[0156] In effect these losses convert to heat in situ between combustors102 and 129 and thereby convert to useful fuel endothermically with somerise in sensible heat in the products flowing to combustor 129.

[0157] At least in the foreseeable future, advanced gas turbines aredesigned for temperatures up to 2800 F with blade cooling and combustorpressure up to 30 atmospheres. This invention has no practical highlimit for the stagnation pressure in combustor 102, even if advanced gasturbines are planned for much higher pressures than 30 atmospheres, orhigher pressure process hydrogen uses are available.

[0158] In view of these boundary conditions the stagnation pressuredifference between combustors 102 and 129 must also be reconciled withthe endothermic heat requirement for the transformation and the sensibleheat content or the product fuel gas and the aerothermochemicalpropulsion design. This heat utilization must primarily take intoaccount that portion of the exhaust heat from the turbine and the heatof compression that delivers it to the rocket engine—conserved energyreactor sequence. For example, in applications where there is a largedifference in pressure between combustors 102 and 129, it is moreexergetic for the rocket engine compressor means to deliver the exhaustgases to the entrainment train toward the lower end of the pressurecascade but still above design pressure at 129.

[0159] On the other hand, when the pressure at 129 is well below thehigh pressure that the state of the advanced art (i.e. 30 atmospheres)for gas turbines, like 20-25 atmospheres, then the preferred mode is tooperate the flow at 212 through compressor 213 at maximum (i.e. equal to210). This relates to zero flow at 211 and simplifies the cycle balancewith respect to consistent chemical aggregate in mass flow.

[0160] Besides considering how varying the foregoing flow effects thedesign pressure at combustor 129, the main criterion is ultimatelychoosing a cycle balance that achieves the most net work output from theturbine means with the most recovery from recycling a related optimum ofexhaust gases. This criterion requires iterating the design pressure toa value lower than 30 atmospheres, as for applications at lowerpressures for retrofitting existing gas turbines operating up to 25atmospheres. This will be covered further in the next embodiment.

[0161] Returning to the rocket engine compressor means, the fuelfraction, line 316, is sized for compressing the selected mass flowthrough compressor 134. Since the internal second law irreversible heatsare adiabatically conserved, ideal isentropic relations can be used atleast as a first approximation for determining the net work from turbineexpansion.

[0162] To illustrate turbine inlet temperature control and the recyclefunctions of this invention, the simpler mode whereby CH₄ is firedwithout transformation follows:

CH₄+2O₂+4.5[CO₂+2H₂O]→{CO₂+2H₂O+4.5[CO₂+2H₂O]}ΔH=−191.7 kcal at 2515 F

[0163] Liberty is taken for simplicity and as a safe side analysis ofthe turbine work for the above, by using Keenan and Kaye Gas Tables for200% Theoretical Air. This represents one pound mole of any gas at 2515F and 25 atmospheres expanded to one atmosphere and 943 F: 25atmospheres 2515 F. h₁ = 23753 Btu/pound mole of products  1 atmosphere 943 F. h₂ = 10275 h₃ = 13478

[0164] h₃ represents the ideal expansion work of the turbine.

[0165] 200% theoretical air relates to a combustion product averagemolecular weight of 28.9 whereas the average for 5.5[CO₂+2H₂O] is 26.7.The safe side value for determining the Btu/pound of product is 28.9.The lower value for this follows:

[0166] h₃′=13478/28.9=466 Btu/pound of products

[0167] Total Products Heat=440 pounds×466 Btu/pound=205040 Btu

[0168] Turbine Work Efficiency=Products Heat/Heat Content of 1 mole ofCH₄

[0169] =[205040/344160]×100=59.6%

[0170] or approximately 60% with respect to one mole of methane

[0171] The theoretical minimum for recovery requires the steady statefuel input to be equal in heat to the work of expansion. This is 60% forthis example and relates to 13478 Btu/pound mole of products expandingthrough the turbine means, simply referred hereafter as the turbine.

[0172] The objective is to develop a stagnation pressure in the jetcombustor that is well above the turbine inlet pressure, which is takenhere as 25 atmospheres. A further objective, preferably is to arrangefor a substantial part of the recycle flow to be compressed by jetpropulsion in the near-adiabatic path hereinafter called the tunnel,from the jet combustor to the turbine inlet.

[0173] This is to take advantage of the 5000 F thermodynamic potentialnot feasible with rotating compressors. The lesser efficiency inmomentum transfer is offset because the rise in sensible heat iscontained for expansion so long as the stagnation pressure driving thejet is adjusted upward, and it can be, to deliver the designed turbineinlet temperature.

[0174] The foregoing operation requires two parallel compressors insteadof compressor 134 shown, whereby one compressor delivers a smaller partof recycle flow at a pressure well above the turbine inlet pressure intojet combustor 102 to augment the combustion products and therebyincrease the mass entraining force of the jet. The other compressordelivers the larger portion of the recycle flow into one or moresecondary ports of the tunnel at pressures somewhat less than theturbine inlet pressure to be entrained and boosted in pressure by thejet mass and further as necessary downstream by after-jet propulsion.

[0175] In a simpler mode, the flow from compressor 134 is divided sothat the lesser flow is directed to the jet combustor and the largerflow at the same pressure can be directed just down stream from the jetinto one or more secondary ports of nozzle section 121, or be furthersubdivided for flow into ports 111, 112 and 113 along the tunnel. Inthis mode, jet power is increased as necessary by increasing thestagnation temperature of the jet combustor.

[0176] Another alternative embodying some of either or both functions ofthe foregoing modes with the distinct difference that the tunnel entrypressure of the recycle flows be somewhat less than the turbine inletpressure and that the jet combustor be independently powered by fuel andoxygen at any suitable temperature and pressure within the design limitsof the rocket engine where its pressure is independently developed byone of the compressors in parallel (earlier described and not shown) andconsistently the pressure of the recycle flow would be independentlydeveloped by the other parallel compressor.

[0177] The foregoing modes illustrate the wide range of operations to beselectively determined and optimized by computer analysis and tunneldesign based on advanced gas dynamics for jet propulsion. The objectiveis to apportion the fuel required for the recompressor distribution withrespect to.

[0178] 1. The intermediate compressor means

[0179] 2. The rocket engine stagnation temperature and pressure

[0180] 3. Tunnel jet propulsions

[0181] all in consideration of the portion of exhaust to be recoveredand recompressed within the cycle.

[0182] The following continues the previous example for the case wherebyall the recompressions to 25 atmospheres take place in the intermediatecompressor means and 50% of the exhaust is selected for recycle and heatrecovery. Related Mass (Pounds) CH₄ (moles)  1. Recycle 50% as 2.75[CO₂ + 2H₂O] and split same into two flows of 1.375 [CO₂ + 2H₂O]  2.Total exhaust mass 5.5 [CO₂ + 2H₂O] 440 1.0   3. ½ exhaust mass 2.75[CO₂ + 2H₂O] 220 0.5   4. ¼ exhaust mass 10375 [CO₂ + 2H₂O] 110 0.25  5.Flow (3) is compressed isentropically 220 0.5  by compressor 134  6.Flow (5) is divided equally 110 0.25 1.375 is delivered at 2515 F.turbine inlet temperature  7. The other half 1.375 is delivered to 110combustor 108 for turbine inlet temperature control, i.e. 1.375 [CO₂ +2H₂O] along with fuel product (5)  80 0.500 [CO₂ + 2H₂O]  8. Togetherequal 190 1.875 [CO₂ + 2H₂O]  9. Exhaust (8) is recompressed by 190 0.43additional fuel flowing sequentially into combustor 108 for 190/440 =0.43 10. However 0.43 [CO₂ + 2H₂O] is   34.5 0.08 additionallyrecompressed in-situ as 34.5 pounds 11. Total mass and fuel used forsaid recompressions:  (5) 220 0.50  (9) 190 0.43 (10)   34.5 0.08  444.5 1.01 1.01 × 440 =   444.4

[0183] Although oxygen power is preferred, air is not precluded. Aparallel example with respect to one mole of methane gives:

CH₄+2O₂+7.5N₂+[CO₂+2H₂O+7.5N₂]

CO₂+2H₂O+7.5N₂+[CO₂+2H₂O+7.5N₂]

[0184] This represents a mass flow through the turbine of 580 pounds.Again using work output, h₃=13478 Btu/pound mole/28.9=466 Btu/pound.

[0185] Total heat flow 580 pounds×466.4=270512 Btu

[0186] Turbine Work=(270517 /344160)×100=78.6% with respect to one moleof methane.

[0187] The recovery procedure with air is similar to that described foroxygen. However if half the exhaust heat and related mass is conservedi.e. 21.4%/2=10.7%, then the work output becomes 78.6+10.7=89% of theheat content of one mole of methane.

[0188] The reason the air mode in these comparisons is more efficientthan the oxygen mode is because the mass flow is proportionately larger.The mass flow in each case was computed on the basis of the same turbineinlet temperature of 2515 F and 25 atmospheres whereby the heat capacityof 440 pounds of the [CO₂+2H₂O] function is significantly greater thanthe [CO₂+2H₂O+7.5N₂] function. This points up another great advantage ofthe oxygen mode i.e. by increasing the mass flow of oxygen mode to thatof the air mode the same work output of 78.6% would develop with thesame heat recovery for a total of approximately 89% but a commensuratelylower turbine inlet temperature for the same power and therefore morebeneficial in turbine design.

[0189] The following can be further deduced from the foregoing analysis:

[0190] 1. When a thermal efficiency somewhat less than 100% is shown fora continuous mass flow (as 440 pounds in the example), then theincreased fuel and compression heat representing 100% must redound in anincreased turbine inlet temperature. So, if the designed turbine inlettemperature is at the metallurgical limit, then the recycle andrecompression must be recast to comply. Otherwise the increasedtemperature results in more turbine output work at steady state loads.

[0191] 2. On the other hand, as a corollary to step 1 by recycling moreexhaust than exemplified, the mass flow from recompression flowadditions will increase over the 440 pounds and disrupt the requiredcontinuity for steady state recycle. In this case the surplusrepresenting surplus heat can be transformed into fuel and be bypassedto contribute to the fuel requirement for any one or more for the rocketengine via the intermediate compression means, and jet propulsionoperations.

[0192] 3. When transformation of carbonaceous matter is introduced(which can be methane) into step 1 or 2, the result is more fuel and/ormore heat which must be taken into account.

[0193] 4. Except for exhaust portion which is not recycled and its heatcontent which can be independently used, the recycle part of the exhaustand all its recompression heat and fuel additions are adiabaticallycontained and must be taken into account in the heat and materialbalance for turbine flow continuity with surplus heat and mass bypassedas converted fuel to replace a corresponding amount in the baseanalysis. The by-pass is necessary to preserve said continuity ofturbine flow.

[0194] The foregoing analysis demonstrates that methane or any cleanfuel can be processed according to this invention without transformationby recycle of a substantial part of the turbine exhaust, its heatrecovery being adjusted for turbine inlet temperature control andcontinuity. Further, this invention provides for heat and pressure forturbine expansion or transforms said heat and pressure into fuel forsaid expansion by a staged engine operation from which practically noshaft output work is delivered, but which converts all shaft workin-situ into heat and pressure for said expansion directly or indirectlyby transforming carbonaceous matter into fuel in a near-adiabaticcontrol volume. In other words, this is a near total energy controlvolume whereby all energy sources entering result in a flow with heatand pressure being delivered for turbine expansion or fuel for turbineexpansion.

[0195] This invention is not limited to how the recovery of export massand heat is obtained. An extraordinary recovery can be made by shortcircuiting a fraction of the turbine exhaust by by-passing the mass flow203 through compressor 205, becoming hotter flow to 203. This flow isproportionately distributed so that the heat recovery between one ormore stages preferably, but not necessarily, equalizes the flow betweenstages of turbine means 200.

[0196] Further, selected mass flow 203 not only adds heat at selectedinterstage locations, but more significantly it admixes, boosts pressureselectively and augments parent flow 214, passing as distributed throughthe stages of turbine means 200. To maintain continuity, constant mass203 branches off augmented flow 202, so that 202 then becomes flow 204which sequentially becomes remnant exhaust flow 207 after flow 206 isbypassed for heat recovery indirectly within the cycle or exported forplant use. A particular advantage of the short circuiting cycle is toincrease the work output without disrupting the mass flow continuityessential in the main cycle.

[0197] Case 2—Rocket Engine Power Source for Turbines with ParasiticShaft Work

[0198]FIG. 3 shows this embodiment whereby the rocket engine powersource is applied to existing gas turbines and the flow from theconserved energy reactor is directed for clean-up at low pressures. Case1 was presented, for transformations wherein the carbonaceous matterflowing into nozzle 120 via line 124 is either pre-cleaned or clean atthe start. In this case, clean-up is presumed necessary and thisrequires that the flow from the conserved energy reactor is dischargedat whatever pressure and temperature is needed to accommodate any one ofseveral commercially available processes.

[0199] Hot gas clean-ups operating at about 1000 F are preferred,because the cleaned gas at this temperature can then flow to the gasturbine at least retaining this level of heat. On the other hand, theadvanced kinetic activity previously described for this invention cancomplete transformation reactions at very low temperatures without heatdegradation from quenching. A further advantage for example, is that thecarbon dioxide fraction in the fuel gas can be extracted at lowertemperatures and pressures for other uses.

[0200] In these cases the conversion efficiency employing the rocketengine powered conserved energy reactor can be better than 90%. Thisreduces fuel cost compared with current practice. Further, when a lowcost residual oil or petroleum coke can be substituted for natural gas,fuel cost can be reduced an additional 50 to 250% or more, depending onmarket prices.

[0201] It is also appropriate for this case to consider the benefits ofservicing a retrofit operation with a clean or pre-cleaned fuel. Thisbrings into play much of the process described in Case 1.

[0202]FIG. 3 illustrates a process wherein all or most of the load ofstandard compressor 300 is relieved so that in effect standard gasturbine 200 is transformed into a free-power turbine whereby the formerload of turbine 200 now becomes additional power output at 201.

[0203] Accordingly, the compressor 300, only as a matter of convenience,can be used for low pressure oxidant flows into the conserved energyreactor through line 301.

[0204] Case 3—Multiple Turbine Arrangements

[0205]FIG. 4 shows a multiple turbine embodiment whereby recycle forturbine inlet temperature control is optimized. The use of oxygen isalso effective when applied to multi-stage turbines by this invention.

[0206] Several process modes are described:

[0207] A. First consider partial oxidation of methane by thermochemicaltransformation for direct interchange with recycle turbine exhaustgases. Some methane is fired in combustor 102 through line 401; theremainder is fired through line 124. The recycled exhaust gases arecompressed at 134 and first proportioned so that compatible flow 208 issized for the turbine inlet temperature of turbine 108. Accordingly,compatible exhaust 210 is largely compressed in 215 and delivered athigh pressure along the conserved energy reactor. The remaining lesserflows 402 and 403 can be optionally applied or turned off.

[0208] The remaining large part of compressor discharge 404 is thendivided to suit the temperature and pressure interaction betweencombustor 102 and jet entrainment nozzle 120. The reaction zones can beapplied as needed. Separator 405 is omitted. Nozzle 406 provides theback pressure for the flow on to top combustor 407. The partiallyoxidized gas continues on through combustors 408 and 409 to exhaust frombottom turbine 410 in complete combustion to exhaust in line 202. Oxygenis supplied through line 411 and controlled for flow content andpressure (not shown) into lines 412, 413 and 414. The control is formaintaining preferably equal temperatures at each interstage to matchthe temperature in combustor 407.

[0209] B. Methane can also be fired with a shortage of oxygen resultingin gas flow that is partially oxidized and be treated as explained in Aabove.

[0210] C. The thermochemical activity between methane and steam can varydepending on temperature and pressure. Either of the following reactionscan be obtained over a wide temperature range:

CH₄+H₂O_((g))

CO+3H₂  Equation (1)

CH₄+2H₂O_((g))

CO₂+4H₂  Equation (2)

[0211] However the reactivity with coal/carbon can be applied to theprocess:

C+H₂O_((g))

CO+H₂  Equation (3)

CO+H₂+H₂O_((g))

CO₂+2H₂  Equation (4)

[0212] All the foregoing reactions are endothermic and operate withinthe heat and reactant content of the recycle part. In this way the cyclefirst yields the endothermic heat and reactant steam for thetransformation and then regains it when the product fuel gas is fireddownstream. The reaction equilibrium is well served by the abundantwater vapor content of the recycle part.

[0213]FIG. 5 shows an embodiment whereby the production of hydrogen ispreferably accomplished via steam—iron reactions. Either of thefollowing three ways are described for their different physical effectsin reaction equilibrium and kinetics with respect to how the ironproduct can be later stored and used:

[0214] A. Reduction of Fe₃O₄ to FeO for Hydrogen

[0215] B. Reduction of Fe₃O₄ to Fe (sponge iron) for Hydrogen

[0216] C. Carburization of Fe to Fe₃C (iron carbide)

A—Reduction of Fe₃O₄ to FeO for Hydrogen

[0217] Heat Source for and Production of the Reducing Gas$\begin{matrix}{{{0.5C} + {0.5O_{2}} + {1.88N_{2}}}\overset{{- 47}\quad {kcal}}{\rightarrow}\quad {{0.5{CO}_{2}} + {1.88N_{2}}}} & {{Equation}\quad (1)} \\{{{{H_{2}O_{(l)}} + {2C} + {0.5O_{2}} + {1.88N_{2}}}\overset{{+ 15}\quad {kcal}}{\rightarrow}{{2{CO}} + {1.88N_{2}} + H_{2}}}{{{Net}\quad {\Delta H}} = {{- 32}\quad {kcal}}}} & {{Equation}\quad (2)}\end{matrix}$

[0218] Reduction

[0.5CO₂+2CO+H₂+3.76N₂]+3Fe₃O_(4(s))→2.5CO₂+H₂O_((g))+9FeO_((s))+3.76N₂  Equation(3)

[0219] Oxidation

9FeO_((s))+1.5H₂O_((l))+1.5H₂O_((g))→3Fe₃O_(4(s))+3H₂ΔG=−93kcal  Equation (4)

[0220] FeO particles, derived from fairly sizable Fe₃O₄ particles(probably from a pellet source), offer a unique characteristic wherebythe particles can lumber along forward from drag forces created by thehigh velocity, reacting steam exerting slip velocities up to transonicspeeds. As a recycle process only the product hydrogen has to bedischarged at the end of the reaction zone. It does not matter if solidsrecycling are a mixture of Fe and FeO particles so long as suitablemeans are provided to preclude agglomeration in recycle. The orientationof the reactor by this invention can assume any angle with horizontalthat sustains the solid particles in flight.

[0221] An alternative mode relates to a very fine Fe particle in the 50to 200 micron range. At the lower end close to dust in size they must beconveyed by a neutral gas, nitrogen for example, in a sealed conduit topreclude spontaneous combustion. Because of this characteristic they canbe expected to develop very high reaction rates just by mixing withsteam. Further comments will ensue after examining the followingreactions for producing hydrogen from sponge iron, Fe:

B. Reduction of Fe₃O₄ to Fe (Sponge Iron) for Hydrogen

[0222] Heat Source $\begin{matrix}{{{0.5{CH}_{4}} + O_{2}}\overset{{- 958}\quad {kcal}}{\rightarrow}{{0.5{CO}_{2}} + {H_{2}O_{(g)}}}} & {{Equation}\quad (1)}\end{matrix}$

[0223] Reforming $\begin{matrix}{{{{CH}_{4} + {0.5{CO}_{2}} + {H_{2}O_{(g)}}}\overset{{+ 39.3}\quad {kcal}}{\rightarrow}{{CO} + {3H_{2}} + {0\quad 5{CO}_{2}}}}{{{Net}\quad {\Delta H}\quad {for}\quad (1)\quad {and}\quad (2)} = {{- 56.5}\quad {kcal}}}} & {{Equation}\quad (2)}\end{matrix}$

[0224] Reduction $\begin{matrix}{{{CO} + {3H_{2}} + {0.5{CO}_{2}} + {{Fe}_{3}O_{4}}}\overset{{+ 26}\quad {kcal}}{\rightarrow}{{1.5{CO}_{2}} + {3H_{2}O} + {3{Fe}}}} & {{Equation}\quad (3)}\end{matrix}$

[0225] Oxidation $\begin{matrix}{{{3{Fe}} + {4H_{2}O_{(g)}}}\overset{{- 358}\quad {kcal}}{\rightarrow}{{{Fe}_{3}O_{4}} + {4H_{2}}}} & {{Equation}\quad (4)}\end{matrix}$

[0226] according to Gahimer et al (IGT experiments 1976) Equation (4)has a favorable free energy change almost linearly from ΔG=−20 kcal at125 C to about −3 kcal at 925 C. The free energy changes for reactions“A” were computed from Thermochemical Properties of Inorganic Substancesby I. Barin and O. Knacke. In view of Gahimer, the favorable free energychanges for the “A” reactions support both processes as achievable forhydrogen production by the rocket engine power source and the conservedenergy reactor. This is not to preclude running larger particle sizes in“B” reactions while still striving for an all-Fe or sponge ironproduction for other uses while producing hydrogen for fuel cells andgas turbines. Such a use is sponge iron for steel mills presented nextas “C.”

C. Carburization of Fe to Fe₃C (Iron Carbide)

[0227] The production of sponge iron is basically the direct reductionof iron oxides as described above and its use in steel is primarily toform iron carbide (Fe₃C). With methane, as a major constituent ofnatural gas, the chemical environment is described by equation (1):$\begin{matrix}{{{CH}_{4} + O_{2}}\overset{{- 64}\quad {kcal}}{\rightarrow}{{CO} + {H_{2}O_{(g)}} + {2H_{2}\quad {Partial}\quad {Oxidation}}}} & {{Equation}\quad (1)}\end{matrix}$

[0228] The following are the driving carburization reactions:$\begin{matrix}{{{3{Fe}} + {CH}_{4}}\overset{{+ 22.9}\quad {kcal}}{\rightarrow}{{{Fe}_{3}C} + {2H_{2}}}} & {{Equation}\quad (2)} \\{{{3{Fe}} + {2{CO}}}\overset{{- 362}\quad {kcal}}{\rightarrow}{{{Fe}_{3}C} + {CO}_{2}}} & {{Equation}\quad (3)} \\{{{3{Fe}} + {CO} + H_{2}}\overset{{- 26.4}\quad {kcal}}{\rightarrow}{{{Fe}_{3}C} + {H_{2}O_{(g)}}}} & {{Equation}\quad (4)}\end{matrix}$

[0229] The foregoing illustrates the expansive applicability of therocket engine power source of relatively unlimited high pressure rangeand a 5000 F ceiling for the rocket engine combustor as a facility forhigh productivity in steel mills with a coordinated process which -alsoproduces power. The combination for this is next described with respectto reactions “B” above and FIG. 5.

[0230] The sequence now is to generate for example, six moles ofhydrogen independently from the above equations by transforming methanein the rocket engine power source. The hydrogen flow is divided equallyinto three tracks:

[0231] Track 1 delivers two moles to fuel cell 500 (preferably solidoxide fuel cells) delivering power and high pressure steam intocombustor 501 which empowers turbine 502, as shown.

[0232] Track 2 delivers two moles of hydrogen directly to combustor 501

[0233] Track 3 delivers two moles of hydrogen to reduce 0.5 Fe₃O₄.

[0234] What follows next are the potential reactions in the first andsecond stage operations. The first stage produces all the hydrogen andis a pressure cascade. It empowers the second stage for the reduction ofFe₃O₄. The pressure developed in rocket engine 503 also delivers theoff-gases in track 3 from reactor 504 into the combustor 501 for maximumheat utilization. The reactions occurring in stage 1 are:$\begin{matrix}{{{0\quad 5{CH}_{4}} + O_{2} + {2H_{2}O_{(l)}}}\overset{{- 71.8}\quad {kcal}}{\rightarrow}{{0.5{CO}_{2}} + {3H_{2}O_{(g)}\quad {Combustion}}}} & {{Equation}\quad (5)} \\{{{1.5{CH}_{4}} + {0.5{CO}_{2}} + {3H_{2}O_{(g)}}}\overset{{+ 54.3}\quad {kcal}}{\rightarrow}{{2{CO}_{2}} + {6H_{2}\quad {Transformation}}}} & {{Equation}\quad (6)}\end{matrix}$

[0235] Reaction 5 takes place at top pressure inside combustor 503 sothat the combustion nozzle develops a jet as needed up to transonicvelocities thereby activating reaction (6) which occurs when 1.5 molesof methane are metered to react with the jet, accordingly producing inthis example six moles of hydrogen equally distributed as abovedescribed to the three tracks. The carbon dioxide is separated from thehydrogen by suitable advanced means for retaining pressure and heat anddirected from reactor 505 from said separation and on to empower thesecond stage sequence 506 and 504 for reducing the magnetite Fe₃O₄.

[0236] Accordingly, carbon dioxide and hydrogen flowing into jet pump506 extend the back pressure from stage 1 through a transonic nozzle tointeract with Fe₃O₄ particles being metered downstream of the carbondioxide and hydrogen jet according to the following reaction (7):$\begin{matrix}{{{2{CO}_{2}} + {2H_{2}} + {0.5{Fe}_{3}O_{4^{(s)}}}}\overset{{- 17.5}\quad {kcal}}{\rightarrow}{{2\quad {CO}_{2}} + {2H_{2}O_{(g)}} + {1.5{Fe}_{(s)}\quad {Reduction}}}} & {{Equation}\quad (7)}\end{matrix}$

[0237] The foregoing reactions are approximately in heat balance so thatadditional heat may be added as necessary for process purposes. This issimply an example of the versatility of this invention to facilitate atwo stage reaction process. The jet pump 506 can readily be organizedfor combustion by introducing oxygen to fire a fraction of the hydrogen,and this can be the case when the carbon dioxide must be separated by aconventional solvent absorber-stripper or pressure swing adsorptionsystem.

[0238] The exhaust from turbine 502 comprises water vapor and carbondioxide. The flows in the process would be iterated (not done for thepurpose of this example) as described in previous embodiments whereby asubstantial fraction in line 507 would continue on in line 508 intorocket engine compressor means 509 and the difference in line 510bypassed for other uses.

[0239] Returning now to the production of iron carbide and usingendothermic reaction (2) for example, sponge iron and methane react withheat to yield iron carbide [Fe₃C] and hydrogen. As an option, this isdepicted in FIG. 5 as a third stage process whereby the methane ispartially oxidized in the rocket engine combustor 511. Methane may bemetered in excess into the nozzle section of combustor 511 or metereddown stream into nozzle sections of sponge iron reactor 512 The jet fromcombustor 511 accordingly supplies the endothermic heat of reaction toproduce are iron carbide and hydrogen. In alternate modes the hydrogenproduced from reactor 512 can be recycled to the nozzle sections ofcombustor 506 and reactor 504 to reduce Fe₃O₄ and/or FeO to sponge ironthereby minimizing carbon dioxide production.

[0240] In conclusion for this embodiment two further points are made.Firstly, a full power plant or peak load requires operating tracks 1 and2 together. In this way the turbine can be organized to handle the baseload on track 2 alone. Secondly, sponge iron can be commercially madeinto pellets or briquettes which can be conveniently ground into powderform. The reactivity of fine iron particles with steam can produce Fe₃O₄and pure hydrogen. This can be more suited for small fuel cells forresidences, for example. Polymer electrolyte membrane fuel cells arecommercially being developed for this purpose as well as somewhat largerunits for commercial buildings or mobile power sources. This class offuel cell minimizes high temperature components in dwellings andconfined spaces. This invention can produce the sponge iron for these orother fuel cell types with relatively small reactors for portability andsecurity as well as the aforementioned larger scale operations.

[0241] We next describe the rocket engine power source applied in twoways for boilers and steam turbines.

[0242] The Steam Turbine Power Cycle—General Considerations

[0243] Refer to FIGS. 6 and 7 which are later described in detail.Typically steam turbines in boilers are without connected compressors.As an example, a steam turbine generator producing 50 MW would bepowered by a boiler delivering approximately 346,000 pounds of steam perhour at 600 psia and 1000 F with an exhaust from the turbine at 250 Fand 30 psia as dry saturated steam containing 1517 Btu per pound.Entropy is approximately 1.7 Btu/pound R.

[0244] At constant entropy, the theoretical efficiency, neglecting pumpwork, is calculated as follows:

E={[1517−1164]/[1517−218]}×100=27.2%

[0245] The efficiency represented sets the point of departure betweenexisting or new installations planned on the Rankine Cycle and thisinvention. The objective here is to recover most of the heat into theconserved energy reactor for converting and developing all the fuel,retaining recovered heat for firing the boiler. In completing the cycle,the efficiencies of the boiler and of the transmission of power betweenthe turbine and generator will remain substantially unchanged. However,the inner cycle gain in entropy increasing the exhaust enthalpy will berecovered in the conserved energy reactor which will receive the exhauststeam directly as the major companion reactant with carbon andhydrocarbon compounds.

[0246] The latent heat in the turbine exhaust represents the largestpart of the waste energy. At least 50% of it is recoverable byinter-mixing an additional flow of water with the turbine exhaust steamon a one to one basis. If all the latent heat is recoverable at thispoint in the process then the usual boiler efficiency of about 90% (100%for simplicity) would also hold as the overall thermal efficiency forthe advanced operation. However the 27.2% efficiency shown above alsorepresents the overall thermal efficiency of a current operation. Thelost energy is 72.8%, which for practical purposes is the latent heatloss to cooling water. By recovering 50% this, as above described “E”becomes:

E=27.2+36.4=63.6%

[0247] The net work is nominally unchanged as 50 MW or 27.2% of the heatflow to the turbine. The fuel economy is greatly increased so that 36.4%less fuel is needed to produce the same net work. Further, the coolingwater requirement is cut in half and the additional water, 50% saturatedafter intermixing is next used as the major water vapor reactant as 2H₂Ointo the conserved energy reactor shown for example, with CH₄ by$\begin{matrix}{{{{CH}_{4} + {2H_{2}O}}\overset{heat}{\rightarrow}{{CO}_{2} + {4H_{2}}}}{{\Delta H} = {{+ 39.5}\quad {kcal}}}} & {{Equation}\quad (1)}\end{matrix}$

[0248] For this analysis and in general two moles of steam can representall the steam that the boiler supplies as 100% and all for the turbine.It is therefore consistent to recover as much heat from two moles ofturbine exhaust by the inter-mix flow transfer, above described, byrelating to two moles for continuity of mass whereby two moles ofexhaust continue on to the condenser and two additional moles with halfof the latent heat go into the reactor which supplies the fuel to theboiler. The added water must at least be as pure as the turbine exhaustso as not to contaminate the flow to the condenser.

[0249] The two moles of water vapor are thereby converted to fuel in thepower source. The fuel is next fired to provide 100% of the heat to theboiler by

CO₂+4H₂+2O₂→CO₂+4H₂OΔH=−221.2 kcal  Equation (2)

[0250] whereby the combustion products CO₂+4H₂O are stack gases (forcleanup as necessary) to become the heat source in near adiabatic flowfor a second stage power source which can provide additional fuel at anypressure for any purpose for immediate use and part of which can berecycled to power the rocket engine and or rocket engine compressormeans for either or both first and second stage reactors.

[0251] It is preferable that in the foregoing staged operations theengines are fired with a clean fuel like methane and that at least instage one the carbonaceous matter is also methane or an equally cleanand compatible fuel.

[0252] The following reaction(s) demonstrate the escalating benefit ofstage two:

CO₂+4H₂O+2CH₄

3CO₂+8H₂ΔH=+79 kcal  Equation (3)

[0253] The effect of firing is shown by:

3CO₂+8H₂+4O₂→3CO₂+H₂ΔH=−462.4 kcal  Equation (4)

[0254] By comparing the combustion heat releases from Equations (2) and(4) with the endothermic requirements of Equations (1) and (3) it isfairly obvious that there is abundant fuel available apart from exhaustheat recovery both as latent and sensible heat from turbine exhaust andstack gases to further supply hydrogen recycle for the rocket engine andcompressor combustors. The carbon dioxide part may be retained orseparated and by-passed by suitable means.

[0255] A yield of eight moles of hydrogen is considered a maximum andthe yield may be considerably reduced by lowering the flow of stackgases for the second stage reactor and directing the difference to lowgrade heat uses. On the other hand this mode, without or with less useof a second stage power source, can apply the first stage in the use ofother carbonaceous less costly and/or less clean feeds which depend onin-situ boiler or stack clean-up.

[0256] Case 5—Rocket Engine Power Source Integrated With Boiler

[0257]FIG. 6 is now described in compliance with the foregoingoperations. FIG. 6 shows this embodiment in which a rocket engine powersource is integrated with a boiler utilizing the two stage fueltransformation. Steam exhaust from turbine 600 via line 601 flow intomixer 602 for direct heat interchange with clean water, through line603, which is metered and pumped (not shown) to boost as necessary theflow through the mixer 602. The nixed flow 604 divides into flows 605and 606 so that flows 601 and 606 are mass-matched (control not shown)to preserve boiler feed water continuity through condenser 607 at acontrolled low pressure which also boosts the mixed flow 604 through themixer 602. As a consequence bypass flow 606 matches the mass content ofclean water inflow 603. Mixer steam flow 608 from boiler 609 joins themixed flows 601 and 603 to bring the clean water flow 603 at least up tothe point of vaporization. The minor steam quantity for this purposebecomes part of and increases bypass flow 606 over said mass-matchedcondition, which now as a partly saturated vapor is directed into adownstream port of rocket engine nozzle section 120 (not shown).Increased flow 606 accordingly becomes the majorH_(2O reactant with carbonaceous matter 610 in the first stage power source. The fuel 611 can be any fuel but clean fuels such as methane or natural gas are preferred for two stage operation. The oxidant 612 is preferably oxygen for the first stage of a two stage operation. The power source discharges fuel product 613 through distribution means 614 which can be the fire box of boiler 609 or simply deliver the fuel product to the boiler's fire box away from said means.)

[0258] The boiler delivers steam 615 which supplies minor bleed 608(previously described) and which can be further divided into a steamflow 616 which directly powers turbine 600 and discharges optional flow617 which is divided into flows 618 and 619 to suit make-up steamrequirements. The optional flow 617 of course requires additional fuelsupply 613 over what is necessary for turbine power.

[0259] There is a second more dominant option for flow 618 whereby theCompressor Means is eliminated and combustion is precluded inside of jetcombustor 102 shown in FIG. 1 and flow 618 (up to full boiler pressure)empowers the jet so that the Rocket Engine is replaced by a powerfulsteam jet pump. However, combustion is not precluded downstream of thejet and can be applied for increasing the temperature and thrust of thedownstream flow. This feature, though not shown, can be applied to thesecond stage Power Source in this embodiment and likewise in the FIG. 7embodiment.

[0260] Continuing now with FIG. 6, steam rich stack gases 620pre-cleaned as necessary inside boiler 609 or outside (not shown), canbe divided into flows 621 and 622. Flow 621 is directed into a port ofnozzle section 120 (shown in FIG. 1) just down stream of the jet. Flows621 and 622 are adjusted to suit the reactivity with flow 622 beingdirected accordingly into the conserved energy reactor. All otheraspects of the second stage reactor are similar to those of stage oneand generally of the Power Source described in FIG. 1.

[0261] Case 6—Hot Flow Extensions of Boiler Embodiment

[0262]FIG. 7 shows this embodiment whereby a boiler arrangement is usedwith a Hot Flow extension to further improve system efficiency. The HotFlow Engine Gasifier is powered by a standard industrial superchargeravailable over a wide flow range, for large industrial diesel engines.In this application, the turbine and compressor part are interspersedwith a custom built combustor designed to be fueled so that combustionproducts are chemically compatible and can flow adiabatically underpower, practically without heat loss, except for minimal radiation forincreasing the efficiency of the Boiler 609.

[0263] The turbocharger engine described is a simple cycle gas turbineand can be started by any suitable means. The turbocharger—gas turbineis preferred to an expensive conventional gas turbine (which is notprecluded) because the pressures anticipated are generally predicted tobe under four atmospheres.

[0264] Referring to FIG. 7 the hot flow unit compressor 700 receives airfrom line 701 and delivers part to combustor 702 from line 703 at toppressure. The remaining air is delivered at the same pressure tocombustor 704. Combustors 702 and 704 are separately fueled by lines 705and 706 respectively by any compatible fuel, but preferably hydrogen inthe ration of 4 to 1 with carbon dioxide, which can be supplied by thesecond stage rocket engine power source. The products accordingly havehigh emissive potential for radiant heat transfer. The products fromcombustor 704 discharge through a sonic nozzle in conjunction withsecondary ports which comprise nozzle entrainment unit 707. The nozzleis integral with the combustor and the secondary entrainment ports whichseparately receive ambient air 708 and exhaust gases 709 from turbine710.

[0265] Extremely hot gases (2000 F and higher) emanate as mixed flowcomprised of combustion products from 704, ambient air 708 and turbineexhaust 709 coming together in channel by suitable means and continue asflow 711 through heat exchanger 712 which further super-superheats theboiler steam 713 to 1600 F and higher. The exit flow 714 can be deployedfor further recovery by conventional heat transfer means to suit variousboiler needs.

[0266] The foregoing completes the hot flow cycle which for practicalpurposes is 100% heat utilization efficient except for minimal radiationand whereby the turbocharger—gas turbine power, converting to heatin-situ, becoming intrinsically part of the total heat, comprises atotal energy conversion adjunct to Boiler 609.

[0267] The hot flow velocities are planned to be very high so as togreatly increase the heat transfer rate in exchanger 712. This is atotal energy system whereby the turbocharger gas turbine's power heatequivalent is totally conserved, resulting in extremely high heattransfer rates because the power for generating the necessarily veryhigh velocities is conserved. As a consequence the ultimate benefit is arelatively smaller heat exchanger. Flow velocity, the essential factor,requires power which rises as the cube of the velocity. Power here isnot a cost factor because it is conserved, as already explainedAccordingly, by combining this intense heat transfer by convection withthe previously described highly emissive radiation, heat fluxes up to90,000 Btu per square foot per hour and higher can be obtained.

[0268] The hot flow extensions to the conserved energy reactor describedabove effectively create a total water and energy recovery system.Investment costs are minimized by the very high heat fluxes therebygreatly reducing the surface area in exchanger 712. Water and itscontained energy is internally recycled; the turbocharger gas turbine'spower heat equivalent is totally conserved; the energy required for highvelocity heat transfer (which rises as the cube of the velocity) is nota factor here because it is conserved, as already explained. Theprinciple advantage of increasing the steam temperature to about 1600 Fand higher is that this substantially increases the turbine output whilestill retaining the conserved energy benefits of the two stage systemand the flexibility of being able to transform considerably less costlyfuels into more useful products. Of course it is also possible to addthe hot flow extension to the fuel cell arrangements described in FIG.5.

[0269] Referring back to and extending the 50 MW example, the followingdemonstrates the Hot Flow gain from just a 400 degree rise to 1400 F,based on a nominal specific heat of 0.5 Btu/ pound F:

E′=[(1717−1164)/(1717−218)]×100=36.9% for 68 MW

[0270] compared with 27.2% for 50 MW. The numbers speak for themselves.Every dollar for fuel heat energy spent in this way is reflected inequivalent electrical energy without loss.

[0271] As apparent from the disclosure, this invention involvesdispensing power in a cascade to one or more prime movers, expansionturbines for example so that the ultimate delivery is electricity ormechanical work. Within the cascade action, hydrocarbon fuels or othercarbonaceous matter are subjected to an aerothermochemical drivingforce, a relatively unlimited stagnation pressure and combustiontemperatures up to 5000 F for delivering jets of compatible formulationto bombard and/or entrain carbonaceous matter introduced downstream. Theconsequence is the production of a fuel gas that is more economical andmore physiochemically suitable for the prime mover. The exhaust from theprime mover is then suitable to a cycle whereby it is recompressed anddelivered at top pressure to the top of the cascade. The part of theexhaust that is bypassed for export can be used to preheat the oxidantand fuel entering the cycle for the recompression of the exhaust. Thefuel for recompression provides a substantial part of the top combustionpressure requirement. Similarly accounted fuel can also be applied forjet propulsion entrainment at one or more locations downstream of thetop jet; that is, between the top jet and the head of the turbine orother prime mover where the fuel gas is fired at the design temperatureand pressure.

[0272] The reactor can transform and provide reactant products for anypurpose, with or without producing electricity. Further, waste heat canbe applied to an endothermic heat requirement for many reactions similarto those described in this invention. Hydrogen and synthesis gases areprovided for ammonia, methanol and other petrochemicals. Ethylene,acetylene and other cracked pyrolysis products are provided fordownstream refining and petrochemical operations. Mixed reactions withsolids such as iron oxides and sponge iron for steel mills and fuelcells also produce exceptional results with this invention. Finally, totemperature and pressure largely are depended upon to drive reactions tocompletion through one or more transonic zones. By metered andcontrolled stoichiometry, with reactions taking place in millisecondsand with the intense gas dynamic action described, kinetic control inprocess operations can be developed over relatively short time spans.Metered and staged stoichionetry in a kinetically controlled reactionenvironment results in autothermal quenching. If desired, conventionalquenching to freeze intermediate reaction species may be employed. Also,catalysts may additionally be employed to promote reaction at lesssevere operating conditions and achieve concurrent removal of sulfur andother pollutants.

[0273] Applying the power source described in this invention to a wholevariety of electric power, chemical and other process uses can fill agreat need in industry and the world.

What is claimed is:
 1. A selective energy conversion source of syntheticfuels, hydrogen and/or related combustion power comprising a rocketengine topping stage provided with fuel and oxidant capable of firing upto 5000 F and higher with relatively unlimited stagnation pressureswhereby said engine powers a jet substantially rich in steam to admitand propel one or more fluids in a near adiabatic tunnel, whereby saidfluids are first pressurized by at least one prime mover for deliveringsaid fluids at conforming pressures into the nozzle section of saidrocket engine and/or downstream nozzle sections in said tunnel andfurther whereby all the mass and substantially all the heat and energydelivered by said prime mover, including recompressed exhaust from saidprime mover, are conserved and come together in said tunnel as a unifiedfluid at a controlled temperature and pressure at the end of said tunnelas a source of said fuels, hydrogen and power;
 2. The process accordingto claim 1 whereby a substantial portion of said fuels and/or hydrogenare recycled to substantially fuel said rocket engine and/or at leastone said prime mover;
 3. A source according to claim 1 whereby saidfuels and hydrogen are clean fuels;
 4. The process according to claim 2whereby said fuels are fired to power gas turbines and expansionturbines;
 5. A source according to claim 1 whereby synthetic fuels areproduced by said transformation reactions occurring in any one or morereactors interspersed between said nozzle sections;
 6. The processaccording to claim 4 whereby said fuels are fired for generating steamin a boiler which can power a steam expansion turbine, whereby a portionof said steam and/or a portion of the exhaust from said turbine recyclesinto the nozzle section of said rocket engine and/or the nozzle sectionsof said tunnel for providing said fuels;
 7. A source according to claim5 whereby said fuels are produced is excess to the requirements for saidboiler and/or said turbine for other uses;
 8. A source according toclaim 1 whereby hydrogen is produced by said transformation reactionsoccurring in any two or more reactors interspersed between said nozzlesections;
 9. The process according to claim 7 whereby said fuels and/orhydrogen are produced by transforming hydrogen containing matter, waterand/or steam which are introduced into any one of said nozzle sectionsto react with said steam rich jet;
 10. The process according to claim 8whereby said synthetic fuels and/or hydrogen are fired to power gasturbines and expansion turbines;
 11. The process according to claim 7whereby said gas turbine is relieved from any in-cycle compression loadand said expansion turbines are precluded from any in-cycle compressionload;
 12. The process according to claim 1 whereby said prime mover alsorecompresses additional recoverable material for delivering same inconforming pressures into said nozzle section of said rocket engineand/or said down stream nozzle sections in order to augment the massflow of the rocket engine;
 13. The process according to claim 11 wherebysaid additional recoverable material is a substantial portion of theexhaust from said gas turbines and/or expansion turbines.
 14. A sourceaccording to claim 7 whereby nitrogen and hydrogen are provided forammonia synthesis;
 15. A source according to claim 13 whereby saidhydrogen is provided for other use;
 16. The process according to claim 1whereby said fuels and hydrogen containing matter are not acceptablyclean when delivered at the end of said tunnel, so then are purified byacceptable means before being used in said gas turbines, expansionturbines and other prime movers.
 17. The process as in claim 13 wherebysaid portion, in recycle, of said exhaust significantly exceeds the massbalance for continuity and the heat balance with respect to the powerexported by said turbines then the excess heat and mass which isadiabatically contained is transformable, in part, to fuel which canreplace, by external recycle, a substantial amount of the fuel requiredby said rocket engine and/or said prime mover.
 18. The process accordingto claim 4 for producing ammonia synthesis gas in one stage with methaneor natural gas as feed stock whereby a fraction of said feed is fired ata suitable pressure with air and water to produce a jet rich in steamfrom the rocket engine whereby the constituents of said jet reactautothermally with a prescribed quantity of said feed stock metered intothe nozzle section of said engine and/or into the nozzle sections insideof said tunnel and down stream of said engine so that reactivity isenhanced with jet flows up to transonic velocities which then produceshock waves as necessary to deliver ammonia synthesis gas with carbondioxide from said tunnel for separation and purification.
 19. Theprocess according to claim 4 whereby two rocket engine stages are usedwith the first stage providing carbon dioxide and hydrogen which are fedinto the nozzle section of the second rocket engine and/or the nozzlesections in the tunnel coupled to said rocket engine, whereby a fractionof the feed methane or natural gas is fired with air and water in eachstaged combustor to produce heat and jets rich in steam and anyunreacted oxygen for subsequent complete oxidation ultimately producinghydrogen and nitrogen in the right ratio autothermally for ammonia andcarbon dioxide to be delivered from said tunnel for separation andpurification.
 20. The process according to claim 19 whereby additionalfuel is produced which is recycled to make up for a substantial portionof the fuel required for said prime mover.
 21. The process according toclaim 19 whereby said reactions produced autothermally are enhanced bycatalysts.
 22. A process comprising an expansion turbine whereby theturbine output is substantially free for useful shaft work with thesubstantial portion of the fluids expanding through said turbine,producing said work, which results from recompression in stages by atleast two independently powered compressors which create pressure fordelivering said output and further whereby practically all the energyprovided for said recompression is conserved in an adiabatic tunnelincluding A. the heat and mass and total energy of said flow, and B. theheat and mass of the fuel fired
 23. The process according to claim 22whereby said expansion turbine is a combustion turbine and said heatsand masses and total energy coming together are conserved in said tunneland are driven into the head of said turbine in a pressure cascade; 24The process according to claim 22 whereby said expansion turbine is asteam turbine;
 25. The process according to claim 23 whereby the fuelfor said combustion is fired with oxygen;
 26. The process according toclaim 23 whereby the fuel for said combustion is fired with air;
 27. Theprocess according to claim 23 when the mass of combustion productsexpanding through said turbine is equal in mass to the mass when air isused, the work output is equal but a lower turbine inlet temperature isobtained than when using the equivalent mass flow for said air;
 28. Theprocess according to claim 27 whereby the temperature with respect tooxygen is increased to match temperature with respect to air for equalmass flows, then the output with respect to oxygen is significantlygreater than for air;
 29. The process according to claim 23 whereby theheat capacity for the mass flow through said turbine can be adjusted bycontrolled recycling and with respect to firing with oxygen controlflexibility is considerably greater than said control flexibility thanwhen firing with air, and which for the same mass, results in lowerturbine inlet temperature.
 30. In a gas turbine process whereby theoutput of the turbine is substantially reduced by reducing the load ofits combustion air compressor on the same shaft, whereby said load issubstantially eliminated by a system of at least two independentlypowered and staged compression operations recompressing the greaterportion of the exhaust from said turbine whereby the heats and massesand total energy from said operations come together near totallyconserved in a near adiabatic tunnel and are driven thereby in apressure cascade into the head of said turbine.
 31. A process ofproducing power comprising: providing a turbine adapted to generateshaft work, said turbine having a combustor; and a rocket engine havinga nozzle and a compressor means; feeding fuel and oxidant to the rocketengine and the rocket engine compressor means; feeding carbonaceousmatter and water and/or steam to the rocket engine nozzle; processingthe output of the rocket engine nozzle into fuel for the turbine;introducing said fuel and oxidant for the turbine to the turbinecombustor; passing the combustion products through a turbine; recyclinga substantial portion of the hot exhaust from the turbine to the rocketengine compressor means; and controlling the inlet temperature to theturbine.
 32. The process according to claim 31 wherein said output fromsaid rocket engine nozzle and said recycled hot exhaust gas from saidturbine are transformed in a near-adiabatic tunnel into said fuel forsaid turbine.
 33. The process according to claim 32 wherein saidtransformation in a near-adiabatic tunnel into said fuel for saidturbine comprises introducing carbonaceous matter and water and/or steaminto said output of said rocket engine nozzle downstream of said nozzleat speeds sufficient to transform said carbonaceous matter into saidfuel for said turbine.
 34. The process according to claim 33 whereinsaid carbonaceous matter and said fuel are selected from the groupconsisting of crude oil, petroleum fractions, coal, char, biomass,natural gas liquids and methane.
 35. The process according to claim 31wherein said transformation occurs in one transformation reactor or agroup of transformation reactors.
 36. The process according to claim 35wherein water and/or steam is introduced into said transformationreactor or group of transformation reactors, thereby reacting in saidreactor or reactors with said output of said rocket engine nozzle andrecycled output of said compressor means to form hydrogen.
 37. Theprocess according to claim 36 wherein at least a portion of saidhydrogen is diverted to one or more downstream uses selected from thegroup consisting of fuel cells, iron oxide reduction reactors, otherturbines, and chemical processes.
 38. The process according to claim 31wherein said transformation occurs in a group of transformation reactorsand the pressure in said output of said rocket engine compressor meansis controlled to conform with the pressure in each transformationreactor.
 39. The process according to claim 31 wherein a portion of saidhot exhaust from said turbine combustor is compressed in an intermediatecompressor for interstage heat additions between two or more stages ofsaid turbine.
 40. The process according to claim 31 wherein said outputof said rocket engine nozzle exits from said nozzle at transonic speeds.41. The process according to claim 31 wherein catalyst for saidtransformation is introduced into said output of said rocket enginenozzle.
 42. The process according to claim 31 wherein said shaft work isfor electrical generation.
 43. The process according to claim 31 havingmore than one turbine and more than one combustor and more than oneelectrical generation means.
 44. The process according to claim 31wherein supplemental or interstage oxidant is added to said turbinecombustor(s).
 45. The process according to claim 31 wherein oxidant isintroduced in said expansion turbines at controlled temperatures. 46.The process according to claim 31 wherein one product of saidtransformation is hydrogen.
 47. A process of producing power comprising:providing a steam turbine adapted to generate shaft work; and a rocketengine having a nozzle and a rocket engine compressor means; feedingfuel and oxidant to the rocket engine; feeding carbonaceous matter andwater, and steam or a water-steam mixture to the rocket engine nozzle;processing the output of the rocket engine nozzle into a heat source fora boiler; boiling water in said boiler to produce water vapor; using theresultant water vapor to power said steam turbine.
 48. The processaccording to claim 47 wherein said clean water is introduced in anapproximately equal weight ratio or more with hot exhaust from saidsteam turbine.
 49. The process according to claim 48 further providing aheat source for a second rocket engine power source transforming theoutput of said second power source into a fuel product.
 50. The processaccording to claim 47 wherein said fuel product comprises hydrogen. 51.The process according to claim 50 further including providing a heatexchanger; a third rocket engine having a nozzle; a turbine having acombustor; feeding fuel and oxidant to said third rocket engine;directing the output of said third rocket engine nozzle into said heatexchanger so as to cool said output and to superheat steam from saidboiler; and transferring the resultant superheated steam to said steamturbine.
 52. Apparatus for generating power from fuel comprising: a gasturbine having a combustor; a rocket engine having a nozzle and acompressor means; means for feeding fuel and oxidant to the rocketengine and to the rocket engine compressor means; means for feedingcarbonaceous matter and water, steam, or a mixture of water and steam,to the rocket engine nozzle; means for processing the output of therocket engine nozzle into fuel for the turbine combustor; means forintroducing said fuel and oxidant for the turbine to the turbinecombustor; means for recycling hot exhaust from the turbine to therocket engine compressor means and controlling the inlet temperature tothe turbine.
 53. The process according to claim 1 whereby said cycle asa first stage power source provides for the production of hydrogen by areaction of water vapor with any one of the following reactingcarbonaceous materials in the conserved energy reacting system by orderof preference:
 1. methane
 2. natural gas
 3. coal carbon
 4. biomass 5.char
 6. any hydrocarbon whereby said reacting system which is activatedby up to a transonic flow of the combustion products and additionalentrained combustion products, whereby the energies for both saidcombustion products are developed by firing oxygen and any fuel that iscompatible with said reaction and whereby the energy of said additionalproducts provide the compression energy for said transonic flow so thatthe hydrogen produced accordingly can now be divided into three tracksfor three interrelated processes whereby
 1. the hydrogen in track oneempowers a fuel cell operation and the resulting water vapor exhaust ina pressure cascade from said first stage power source flows on to firewith oxygen as the combustion energy for developing power by expandingthe combustion products of said energy;
 2. the hydrogen in track two isdirectly applied in combustion for developing additional power whichcombines with that of track one by expanding its combustion products;and
 3. the hydrogen of track three combines with the carbon dioxide(which is produced and separated from hydrogen before the hydrogen isdivided into said three tracks) whereby both are now empowered by thecommanding pressure of the first stage to develop a second stagepressurized jet, without combustion, which in turn activates a secondstage conserved energy reactor in which said track three hydrogenreduces iron oxide, Fe₃O₄ injected into said reactor just downstream ofsaid jet so accordingly the following result in: A. Sponge iron (Fe) isproduced B. Carbon dioxide and water vapor still under pressure suppliesadditional heat under said pressure to flow to and combine with othercombustion products in expanding to develop said power
 54. The processaccording to claim 53 whereby any one of said tracks can operate aloneand independently.
 55. The process according to claim 53 whereby trackone and track three are shut down and track two provides the power foroff peak loads.
 56. The process according to claim 53 whereby any one ofthe said three track uses of hydrogen can be independently processed.57. The process according to claim 53 for the third track when thecarbon dioxide from the first stage power source is low pressure orby-passed, whereby a portion of hydrogen from said stage is fired withoxygen in the rocket engine combustor of the second stage and theremaining hydrogen is metered into the nozzle section of said rocketengine combustor to admix metered in at least stoichiometric proportionwith the iron oxide metered into said nozzle section and/or additionalnozzle sections down stream of in the reactor section to produce spongeiron.
 58. The process according to claim 57 whereby the sponge iron isdelivered into the rocket engine nozzle section and/or down streamnozzle sections in a third stage operation whereby the sponge ironreacts with methane, which is partially oxidized in the combustor ofsaid engine, so that the resulting jet with excess methane in suitableproportions reacts with said sponge iron to produce iron carbide andhydrogen.
 59. The process according to claim 1 for the production ofiron carbide in at least two steps whereby methane is partially oxidizedin a last stage rocket engine combustor providing a jet with an excessmethane fraction or methane is metered into down stream nozzle sectionsin suitable proportions for reacting with sponge iron delivered into thenozzle section of said engine and/or down stream nozzle sectionsproducing said iron carbide and hydrogen whereby said hydrogen is thenrecycled into a suitable previous rocket engine reactor to reduce theiron oxide thereby producing a substantial amount of sponge iron. 60.The pyrolysis process according to claim 1 for cracking methane andlargely paraffin feed stocks to largely olefin and diolefin mixtures,methane to ethylene/acetylene and ethane to ethylene for example,whereby a largely steam source is developed in a rocket engine combustorto discharge a transonic jet to interact with feed stock metered intothe nozzle section of said engine and/or down stream nozzle sectionswith said jet accordingly cracking to discharge ethylene and steam forsuitable separation.
 61. The process according to claim 60 wherebystagnation temperatures up to 5000 F and higher and relatively unlimitedstagnation pressures can be developed in said combustor.
 62. The processaccording to claim 61 where the downstream reactor comprises at leastthree optional cracking zones for flexibility locating precise shockzones under various flow velocities and shock related pressuredifferences for a substantial range offered by said relatively unlimitedstagnation pressure in said rocket engine combustor.
 63. The processaccording to claim 62 whereby each of said cracking zones is preceded bya nozzle section for additional reactants and supersonic flows.
 64. Theprocess according to claim 63 whereby additional shock flows can besymmetrically oriented around the central flow at critically strategicpositions as sought by adjusting the synchronization of said shocks byselectively precise control of said flows.
 65. The process according toclaim 64 whereby hydrogen is introduced in conjunction with saidadditional shock flows and said control.
 66. The process according toclaim 60 for producing ethylene whereby synthesis gas co-produced is thepyrolysis gas in a first stage supply in addition to producing somesynthesis gas for export and an additional amount is provided inrecycling as a substantial source of fuel for said rocket engine and/orsaid prime mover so that by difference of the total synthesis gas flow,sufficient synthesis gas is provided for the production of ethyleneaccording to the following procedure whereby synthesis gas at highpressure is delivered in prescribed quantity into the combustor of asecond stage rocket engine and fired therein to produce a suitablepyrolysis jet for cracking methane metered into the nozzle section ofthe rocket engine and/or one or more nozzle sections down stream of thenozzle to said last stage rocket engine;
 67. The process according toclaim 66 whereby said cracking occurs at one or more shock waves
 68. Theprocess according to claim 67 whereby supplementary shocks occur and asa consequence of compatible matter as supersonic flows are directed intoone or more nozzle sections down stream of said jet;
 69. The processaccording to claim 68 whereby said supersonic flows are organized as oneor more symmetrical pairs angling into and fairing into and along themain flow produced by said engine jet as admixed with a prescribedamount of ethane directed into said engine nozzle section and/or one ormore said nozzle sections down stream;
 70. the process according toclaim 68 whereby the shock waves produced by said engine jet and/orthose produced by secondary supersonic flows are suitably coordinatedwith respect to plausible cracking time ranges and the velocity of themain stream to take place in any one or more locations designated forthe entry of said supersonic flows;
 71. The process according to claim70 whereby suitable arrangements are made to at least partially quenchthe product flow by use of the ports at the next nozzle section locationfrom said cracking location thereby delivering said ethylene and somesteam for further quenching and separation beyond this process;
 72. Theprocess according to claim 70 whereby carbonaceous matter is alsoproduced in the first stage for producing the synthesis gas required forpyrolytic cracking in the production of ethylene and otherpetrochemicals.